Structure

ABSTRACT

A structure is disclosed. The structure provides at least one base member, at least one frame member coupled with the at least one base member, and at least one cover coupled with the at least one frame member

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/704,906, titled “STRUCTURE” filed on Sep. 24, 2012, which is incorporated herein by reference in its entirety.

FIELD

The present invention relates to structures. More particularly, the present invention relates to modular structures.

BACKGROUND

The use of conventional bricks for textured purposes within the interior or exterior of a building is well known in the art. Formation of a brick structure involves skilled labor and is beyond the experience of an average home-owner. Moreover, formation of brick structures requires expensive installation equipment. In addition, brick structure tends to deteriorate with time due to growth of roots. Moreover, demolition and removal of such structures is very expensive. Yet another problem is that brick structures are very brittle, thus highly sensitive to earthquakes and can be destroyed or severely damaged by a fairly low intensity earthquake.

Due to the limitations described here-in, in many cases, installation of brick structures is cost prohibitive for an average home-owner. Therefore there is a need for a process and method of constructing structure(s) that will be more economical, easier to install, more reliable and easier to remove.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 depicts faux brick synthetic panel as known in the art.

FIG. 2 depicts an embodiment according to the present application.

FIG. 3: Perspective new of Embodiment 10 base fast connect.

FIG. 4: Perspective view of Embodiment 10 frame connected to base.

FIG. 5: Exploded view of Embodiment 10 fast connect frame to base.

FIG. 6: Exploded view of Embodiment 10 connection of one frame to another.

FIG. 7: Perspective view of Embodiment 10 side panels and caps connected to the frame.

FIG. 8: Partially assembled embodiment 10.

FIGS. 9A-B: Embodiment 10 side panels quick connectors.

FIGS. 10A-C: Embodiment 10 frame bricks quick connectors.

FIG. 11: Exploded view of embodiment 20, structure profiles and connectors.

FIG. 12: Perspective view of assembled embodiment 20, structure profiles and connectors.

FIG. 13: Perspective view assembled frame embodiment 20 structure.

FIGS. 14A-D: Perspective view embodiment 20 textured panels, fast connectors.

FIGS. 15A-B: Perspective view of embodiment 20 frame and textured panels, assembly.

FIG. 16: Perspective view partially assembled embodiment 20 frame, textured panels and covers.

FIG. 17: Embodiment 30 assembly connector and base stake for ground connection.

FIG. 18 Embodiment 40 perforated square profile and textured panel.

FIG. 19: Perspective view embodiment 50 connecting cut profiles.

FIGS. 20A-C: Perspective view of different shape profiles and beams.

FIGS. 21A-C: Perspective view of different shape connectors.

In the following description, like reference numbers are used to identify like elements. Furthermore, the drawings are intended to illustrate major features of exemplary embodiments in a diagrammatic manner. The drawings are not intended to depict every feature of every implementation nor relative dimensions of the depicted elements, and are not drawn to scale.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth to clearly describe various specific embodiments disclosed herein. One skilled in the art, however, will understand that the presently claimed invention may be practiced without all of the specific details discussed below. In other instances, well known features have not been described so as not to obscure the invention.

The present application describes removable and reusable structures made of, for example, synthetic materials which, on the outside, appear like permanent structures made of materials like, for example, bricks, stacked stone, wood beam, and/or bamboo.

The processes and methods described in the present application may overcome the limitations described above and may provide a structure that may be installed by an average home-owner, does not require skilled labor, is light weight, flexible, may be easily removable, and more cost effective. Due to the flexibility of the materials, the presently disclosed structure may be more resilient to earthquakes and growth of roots.

Presently disclosed embodiments describe structure frames, frame connectors, panels and processes for installation of such.

FIG. 1 depicts a synthetic textured panel 5 as known in the art. The panel 5 may be manufactured by creating a flexible mold with the desired texture, such as bricks, stacked stone, wood beam, bamboo and such. The mold may be painted first on the inside with the desired colors and then the filling material is poured into the mold. Common materials used are cement and high density polyurethane foam. Once cured, the panel is removed from the mold. The panels 5 may be installed on existing structures such as stucco, drywall or cement using screws and/or adhesives. Oftentimes the panels are designed to interlock one another. For example, a connecting Tongue 12A would slide over groove 12B of an adjacent panel (not shown), tongue 14A would slide over groove 14B of also adjacent panel (not shown), and so on.

According to one embodiment presently disclosed, a structure 10 is shown in FIGS. 2-8. The structure 10 comprises an interlocking base structure 101 as shown in FIG. 2. The base structure 101 comprises base plates 102. In one embodiment, the base plates 102 are fastened to a surface (not shown) via holes 106 using, for example, fasteners known in the art of construction such as screws, bolts and such. The base plates 102 may be made of rigid or flexible materials to accommodate variation in the flatness of the surface. The base plates 102 may be coupled with one another using, for example, dove tail groove and tongue connection, by sliding each base plate into another as shown in FIG. 3 and described below. Corner base plate 110 may be used to create a corner in the structure 10.

Referring to FIG. 3, the base plate structure 101 may comprise a dovetail shape tongue 116A and a dovetail shape groove 116B. The dovetail tongue 116A of base plate 102A may be slid into the groove 116B of base plate 102B and so on. Once base plate structure 101 is completed, the base plate structure 101 may be fastened to the surface (not shown) via holes 106 using fasteners known in the art of construction.

Referring to FIG. 4, in one embodiment, the structure 10 comprises a frame brick 118 coupled with the plates 102A and 102B of the base structure 101. The frame brick 118 comprises an inner contact surface 1000 configured to couple with the plates 102A and 102B. In one embodiment, the base plates 102A and 102B comprise one or more protrusions 122A configured to interlock with cavities 122B located on an inner surface 1000 of the frame brick 118 (as shown in FIG. 5). In one embodiment, the frame brick 118 may be pressed into base structure 101 using pressure or by knocking it into position using, for example, a rubber mallet. In one embodiment, the protrusions 122A and the cavities 122B are rounded.

In another embodiment, the frame brick 118 comprises an outer surface 120 configured to couple with another frame brick 150 as shown in FIG. 6. In one embodiment, the outer surface 120 of the frame brick 118 comprises one or more protrusions 122A configured to interlock with cavities 122B located on an inner surface 1000 of another frame brick 150 (shown in FIG. 6). In one embodiment, the protrusions 122A and the cavities 122B are rounded. In one embodiment, the frame brick 118 is coupled with the frame brick 150 by pressing frame brick 150 in the direction of the arrow 160. In one embodiment, half sphere connectors 122A of frame brick 118 are fitted into half sphere cavities 122B of the frame brick 150. Similar process may be used to couple other frame bricks to one another. The frame bricks may be connected by stacking them one on top of another or by staggering them as shown in FIGS. 6 and 8. In one embodiment, multiple frame bricks 118 and 150 are coupled with each other and the base plate structure 101 to form the structure 10 of any desired shape.

In another embodiment, the frame bricks presently disclosed are coupled with one or more panels as described next. Referring to FIG. 7, in one embodiment, the frame brick 150 is coupled with a side panel 170. In another embodiment, the frame brick 150 is coupled with a cap panel 190. The side panel 170 and/or cap panel 190 may comprise textured surfaces having an appearance of stone, wood, or building materials such as bricks, stacked stone, etc. Coupling of the frame brick 150 with the side panel 170 and/or cap surface 190 give the appearance of construction structure such as brick wall, wall with stone veneer etc.

In one embodiment, the side panel 170 comprises one or more grooves (not shown) located on an inner surface (not shown) of the side panel 170 configured couple with one or more protrusions 158 associated with the frame brick 150. In another embodiment, the cap panel 190 comprises one or more cavities (not shown) configured to couple with one or more protrusions 122A associated with the frame brick 150.

FIG. 8 depicts a partially assembled structure 10. A fully assembled structure 10 may be shaped per user's/builder's specifications and may appear as masonry brick wall, brick fence, planters, wall with stone veneer, wall with wood siding etc. In one embodiment, the structure 10 may be disassembled and re-assembled in a different configuration by removing the different elements of the structure and assembling them in a different configuration.

FIGS. 9A-9C depict different embodiments for connecting side panel to one or more frame bricks. A panel shown in FIG. 9A may be coupled with a frame brick using a perimeter tongue 200 by pressing the tongue into a similar shape groove associated with the frame brick. A panel shown in FIG. 9B may be coupled with a frame brick using a half sphere protrusion 202 by pressing the tongue into a similar shape cavity associated with the frame brick. A panel shown in FIG. 9C may be coupled with a frame brick using a square tongue 204 by pressing the tongue into a similar shape cavity associated with the frame brick.

FIGS. 10A-10C depict different embodiments of frame bricks comprising different connectors for connecting frame bricks to one another, to base plates and/or cap/side panels. A frame brick shown in FIG. 10A may be coupled with another frame brick using perimeter tongue 206 by pressing the tongue into a similar shape groove associated with another frame brick. A frame brick shown in FIG. 10B may be coupled with another frame brick using half sphere tongue 206 by pressing the tongue into a similar shape cavity associated with another frame brick. A frame brick shown in FIG. 10C may be coupled with another frame brick using square tongue 208 by pressing the tongue into a similar shape cavity associated with another frame brick.

In another embodiment, the cap panels and/or side panels described above are integrated with one or more frame bricks and are not removable.

According to another embodiment presently disclosed, a structure 20 is shown in FIGS. 11-21. Referring to FIG. 11, the structure 20 comprises two or more beams 340A, 340B, 340C, 340D coupled with a connector 302. The connector 302 may comprise one or more protrusions 312A, 312B, 312C, 312D, 312E associated with male connecting pins 304A, 304B, 304C, 304D, 304E. The beams 340A, 340B, 340C, 340D may be coupled with the connector 302 to form the structure 20 by sliding beams 340A-D onto the male connecting pins 304A-D and locking them into position by fitting protrusions 312A, 312B, 312C, 312D, 312E to their matching openings 350A, 350B, 350C, 350D, 350E. The connector 302 may be solid or hollow. The connector 302 may comprise metal material and/or rigid polymer material. The connector 302 may comprise two to six different male connecting pins depending on its position in the structure 20. For example, a connector located in a top edge position will have only three male connecting pins. A connector located in middle bottom position on a face will have five connecting pins. The connector 302 may comprise at least one protrusion to connect to beams.

The beams 340A, 340B, 340C, 340D may comprise a square profile, circular profile, octagon profile, “I” beam profile, “L” beam profile, and/or “u” beam profile. The beams 340A, 340B, 340C, 340D may comprise aluminum material, steel material, rigid polymeric materials such as PVC, flexible polymeric materials such as PVC and/or composite materials.

In one embodiment, the structure 20 may be coupled to a floor surface (not shown) by coupling the connector 302 to a base plate 360 shown in FIGS. 11-12. In one embodiment, the base plate 360 comprises an opening 350E configured to accommodate the protrusion 312E of the connector 302. The base plate 360 may also comprise a beam 366 that may slide over the connecting pin 304E of connector 302.

The base plate 360 may comprise one or more openings 364A, 364B, 364C to allow the base plate 360 to be coupled with the floor surface (not shown) using fasteners known in the art of construction.

FIG. 12 depicts a portion of the structure 20 wherein the connector 302 is coupled with the beams 340A, 340B, 340C, 340D and base connector 360 of FIG. 11. In this manner the structure 20 can be assembled to desired shape, length and/or height.

FIG. 13 depicts frame structure 20 partially assembled. Beams 382A, 382B, 382C, 382D, 382E may be coupled with one another using connectors 384A, 384B, 384C, 384D, 384E (not shown) to form the frame structure 20. The connectors 384A, 384B, 384C may be used to couple the frame 20 with floor surface using, for example, base connectors 386A, 386B, 386C.

In another embodiment, the frame structure 20 presently described is coupled with one or more panels as described below. In one embodiment, a panel 400 shown in FIGS. 14A-B may be coupled with the structure 20. FIGS. 14A and 14B depict a front and back side of the panel 400. In one embodiment, as shown in FIG. 14A, the front side of the panel 400 may comprise a textured surface configured to look like a brick. It is to be understood that other textured surfaces can be applied to the front of the panel 400. In another embodiment, the back side of the panel 400 may comprise a plurality of cavities/holes 402. In one embodiment, the panel 400 may be coupled with the frame 20 by using fasteners like, for example, screws. Screws or other fasteners may be used to connect the panel 400 to a profile such as 382A (shown FIG. 13) by inserting a screw (not shown) through the profile 382A to one of the holes 402.

In another embodiment, a panel 410 shown in FIGS. 14C-D may be coupled with the structure 20. FIGS. 14C-D depict a front and back side of the panel 410. In one embodiment, as shown in FIG. 14C, the front side of the panel 410 may comprise a textured surface configured to look like a brick. It is to be understood that other textured surfaces can be applied to the front of the panel 410. In another embodiment, the back side of the panel 410 may comprise one or more connector pins 412. In one embodiment, the panel 410 is coupled with the structure 20 using the one or more connector pins 412 as shown in FIGS. 15A-B.

FIGS. 15A and 15B depicts partially assembled embodiment structure 20. FIG. 15A depicts a textured panel with the appearance of common cedar bricks 410 being coupled with to structure 20 using connector pins 412. In one embodiment, the connector pins 412 coupled with the structure 20 through holes 408A and 408B. FIG. 15B is an enlarged view of the connection section circled A in FIG. 15A where the connector pins 412 and hole 408B are clearly visible.

In one embodiment, an adjacent textured panel (not shown) is connected to structure 20 where tongues of the panel 410 such as 412A, 412B, 412C may slide over grooves such as 410A, 410B and 410C of an adjacent panel (not shown).

FIG. 16 depicts a partially assembled structure 20 according to the present disclosure. The panel 400 may be coupled with a frame 380 of the structure 20 and another adjacent panel 420. The seam between the panels 400 and 420 may not be visible due to the tongue and groove design described above. In another embodiment, top covers 430 and 440 may be coupled with the frame 380 in a similar manner described in FIG. 15B from the top. A fully assembled structure may give the general appearance of a cedar brick fence and stone top.

FIG. 17 depicts a stake connector 500 configured to couple with the connector 302 described above with reference to FIG. 11. The stake connector 500 is configured to couple the structure 20 with dirt/ground surface. In one embodiment, the stake connector 500 comprises a stake portion 504, a slotted hole 502 to accommodate of ground level variations, a profile 501 to fit male pin 304E of connector 520. The stake connector 500 may be hammered to the ground at the desired location. In one embodiment, the connector 302 may comprise a hole 524 in connecting pin 304E configured to fasten connector 302 to stake connector 500 using a screw, bolt, or any other fastener.

In another embodiment, the structure 20 comprises a beam 550 comprising slotted holes 552 along its faces as shown in FIG. 18. A panel 560 may be coupled with the beam 550 using a bolt or threaded rod 562 coupled with the panel 560. The threaded rod 562 is inserted through one of the slots such as 552 and tightened on the other side using a nut 564.

In another embodiment, a fitting 580 may be used to accommodate length requirements in the structured frame 20 as shown in FIG. 19. Beams 550 described in FIG. 18 above may be cut to required length and its cut parts 570A and 570B may be connected to one another using the fitting 580. Cut edges 576A of profile 570A and 576B of profile 570B may be inserted to fitting 580 and coupled together with a screw 584 or bolt (not shown). Slotted holes 574A and 574B of profiles 570A and 570B may be used to connect textured panels by fasteners known in the art of fastening. Edges 572A of profile 570A and 572B of profile 570B may be connected to the rest of the frame comprising connectors such as 302 described in FIG. 11.

FIGS. 20A-C depict beam profiles that can be used to form the structure 20. FIG. 20A depicts “L” shape beam 600A with slotted holes for connecting to textured panels. FIG. 20B depicts an octagon shape profile 600B that may be used to assemble a frame structure that may comprise different angles of connection and different angles for the textured panels. FIG. 20C depicts a “U” shape beam 600C that may be used to assemble a frame structure.

FIGS. 21A-C depict connectors that may be used to couple beams of the structure 20. FIG. 21A depicts an “L” shape connector 602A that may connect “L” shaped profiles such as 600A depicted in FIG. 20A to assemble a frame structure. FIG. 21B depicts a hexagon connector 602B that may connect hexagon profiles such as 600B depicted in FIG. 20B to assemble a frame structure. FIG. 21C depicts a “U” shape connector pins 602C that may connect to “U” shape profiles such as 600C depicted in FIG. 20C.

All the profiles and connectors described in FIGS. 20 and 21 are methods of assembling the structure 20 to which structured panels and covers may be couple to create a synthetic structure with an appearance such as, for example, a cedar brick wall, a wall with veneer stone, wood siding and such.

Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.

While several illustrative embodiments of the invention have been shown and described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternative embodiments are contemplated, and can be made without departing from the scope of the invention as defined in the appended claims.

As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. The term “plurality” includes two or more referents unless the content clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosure pertains.

The foregoing detailed description of embodiments is presented for purposes of illustration and disclosure in accordance with the requirements of the law. It is not intended to be exhaustive nor to limit the invention to the precise form(s) described, but only to enable others skilled in the art to understand how the invention may be suited for a particular use or implementation. The possibility of modifications and variations will be apparent to practitioners skilled in the art. No limitation is intended by the description of exemplary embodiments which may have included tolerances, feature dimensions, specific operating conditions, engineering specifications, or the like, and which may vary between implementations or with changes to the state of the art, and no limitation should be implied therefrom. Applicant has made this disclosure with respect to the current state of the art, but also contemplates advancements and that adaptations in the future may take into consideration of those advancements, namely in accordance with the then current state of the art. It is intended that the scope of the invention be defined by the Claims as written and equivalents as applicable. Reference to a claim element in the singular is not intended to mean “one and only one” unless explicitly so stated. Moreover, no element, component, nor method or process step in this disclosure is intended to be dedicated to the public regardless of whether the element, component, or step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. Sec. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for . . . ” and no method or process step herein is to be construed under those provisions unless the step, or steps, are expressly recited using the phrase “step(s) for . . . . ” 

What is claimed is:
 1. A structure comprising: at least one base member; at least one frame member coupled with the at least one base member; and at least one cover coupled with the at least one frame member.
 2. The structure of claim 1, further comprising another frame member coupled with the at least one frame member.
 3. The structure of claim 1, further comprising another base member, wherein the at least one frame member is coupled with the another base member.
 4. The structure of claim 3, wherein the another base member is coupled with the at least one base member.
 5. The structure of claim 1, wherein the at least one base member is coupled to ground.
 6. The structure of claim 1, further comprising another cover coupled with the at least one frame member.
 7. The structure of claim 1, wherein the at least one cover comprises a first surface with a brick texture, stacked stone texture, or wood texture.
 8. A structure comprising: at least one beam comprising a first end defining a first opening and a second opening; and at least one connector comprising at least one connection pin defining at least one protrusion, wherein the at least one connection pin is coupled to the at least one beam through the first opening and the at least one protrusion is coupled with the at least one beam through the second opening.
 9. The structure of claim 8, further comprising a base plate coupled with the at least one connector, wherein the base plate is coupled to ground.
 10. The structure of claim 8, further comprising at least one cover coupled with the at least one beam.
 11. The structure of claim 10, wherein the at least one cover comprises a first surface with a brick texture, stacked stone texture, or wood texture.
 12. The structure of claim 8, wherein the at least one beam comprises a second end defining a third opening and a fourth opening.
 13. The structure of claim 12, further comprising a second connector comprising a connection pin defining a protrusion, wherein the connection pin is coupled to the at least one beam through the third opening and the protrusion is coupled with the at least one beam through the fourth opening.
 14. A method comprising: providing a base member; coupling a frame member with the base member; and coupling a cover with the frame member.
 15. The method of claim 14, further comprising coupling another frame member with the frame member.
 16. The method of claim 14, further comprising coupling another base member with the frame member.
 17. The method of claim 16, further comprising coupling the another base member with the base member.
 18. The method of claim 14, further comprising coupling the base member with ground. 